Technical GCRB Information Relay BoxToc> iii TI 11B05B02-03E Introduction Thank you for...

Yokogawa Electric Corporation

TechnicalInformation

<Int> <Ind> <Rev>

GCRBRelay BoxInstallation ManualTI 11B05B02-03E

TI 11B05B02-03E©Copyright Mar. 2002(YK)

2nd Edition Dec. 2006(YK)

Contents

Notice ...................................................................................................................... i

Introduction ............................................................................................................ iii

1. OVERVIEW .............................................................................................. 1-11.1 Description and Ratings .................................................................................. 1-11.2 MS Code ........................................................................................................... 1-11.3 Block Diagram .................................................................................................. 1-21.4 External Dimensions ......................................................................................... 1-31.5 Standard Performance ...................................................................................... 1-41.6 Data Plate ......................................................................................................... 1-5

2. INSTALLATION AND WIRING .................................................................. 2-12.1 Installation ........................................................................................................ 2-12.2 Wiring ............................................................................................................... 2-2

2.2.1 General Cautions on Wiring .............................................................. 2-22.2.2 Kinds of Wiring ................................................................................. 2-22.2.3 Recommended Cables ..................................................................... 2-22.2.4 Precautions on Wiring ....................................................................... 2-32.2.5 Grounding Wire Termination and Signal Cable Shield ....................... 2-32.2.7 Signal Lines ...................................................................................... 2-52.2.7 Terminal connection of shielded signal cables for CENELEC ............ 2-6

Revision Record ............................................................................................ i

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<Toc> <Ind> <Rev> <Introduction> i

TI 11B05B02-03EMedia No. TI 11B05B02-03E 2nd Edition : Dec. 2006 (YK)All Rights Reserved Copyright ©2002, Yokogawa Electric Corporation

Notice

Regarding This Manual1. This Manual should be passed on to the end user.

2. Read this manual carefully and fully understand how to operate this product beforeyou start operation.

3. Yokogawa makes no warranty of any kind with regard to this material, but notlimited to, implied warranties of merchantability for particular purpose.

4. All rights reserved. No part of this manual may be reproduced in any form withoutYokogawa’s written permission.

5. The contents of this manual are subject to change without prior notice.

Regarding Protection, Safety, and Prohibition Against UnauthorizedModification.

1. For the protection and safe use of the product and the system controlled by it, besure to follow the instructions on safety described in this manual when handlingthe product. In addition, if you handle the product in contradiction to theseinstructions, our company does not guarantee safety.

2. The following safety symbol marks are used on the product concerned or in thisManual :

A WARNING sign denotes a hazard. It calls attention to procedure,practice,condition or the like, which, if not correctly performed oradhered to, could result in injury or death of personnel.

A CAUTION sign denotes a hazard. It calls attention to a procedure,practice, condition or the like, which, if not correctly performed oradhered to, could result in damage to or destruction of part or all ofthe product.

IMPORTANT:

Indicates that operating the hardware or software in this manner maydamage it or lead to system failure.

NOTE:

Draws attention to information essential for understanding the opera-tion and features.

Protective ground terminal:In order to provide protection against electrical shock in case of afault. This symbol indicates that the terminal must be connected toground prior to operation of equipment.

Direct Current

!

!

2nd Edition : Dec.18,2006-00

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TI 11B05B02-03E

3. If protection / safety circuits are to be used for the product or the system controlledby it, they should be installed outside of the product.

4. When you replace parts or consumables of the product, use those specified by ourcompany.

5. Do not modify the product.

Exemption from Responsibility1. Yokogawa Electric Corporation does not make any warranties regarding the

product except those mentioned in the WARRANTY that is provided separately.

2. Yokogawa Electric Corporation assumes no liability to any party for any loss ordamage, direct or indirect, caused by the use or any unpredictable defect of theproduct.


<Toc> <Ind> <Rev> <Introduction> iii

TI 11B05B02-03E

IntroductionThank you for purchasing the GCRB Relay Box.

This manual describes the technical information to install the GCRB.

Please read the respective cautions (General Precautions and Cautions of usingexplosion-protection instruments) before installing the GCRB.

WARNING

This instrument must be installed by expert engineer or skilledpersonnel.The procedures described this manual are not permittedfor operators.

System Configuration

PTR

ETHERNET+SERIAL

SERIAL COMM.

DCS BUS

ControlRoom

Field

Remote-MaintenanceANALYZER BUS

Modem

OperaionConsole

Work-station

I/O

GC 1000

1

I/O

RegendGCAS : Analyzer Bus ServerGCIU : GC Interface UnitGCHUB : HUBASMT : Analyzer Server Maintenace

Terminal (Package Software)PC : Personal ComputerPTR : PrinterGCRB : Relay Box

GC 1000

4

GCHUB

GC 1000

1

GC 1000

4

GCHUB

GC 1000

1

GC 1000

4

GCHUB

GCIU GCRB

F0001E.EPS

PC(ASMT)

GCHUB

UPS

GCAS

GCHUB GCHUB GCHUBGCHUB

Analyzer bus system: Used to connect analyzers based on gas chromatograph in thefield to a network. The system has a total redundant configuration for safety.

GCAS (Analyzer Server): The monitor/control center for the entire network. It alsosaves necessary data automatically. Moreover it joints with DCS for serial communica-tion and digital output, etc.

ASMT (Analyzer Server Maintenance Terminal): When this package software isinstalled on an ordinary personal computer, the computer acts as a human interfacededicated to this system.The operator can thus operate gas chromatograph in the field from the computer viaGCAS.

GCIU (Interface Unit): The information of the field sensor except GC is input as theanalog data and can be monitor on ASMT and DCS by the analyzer bus.


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GCHUB: The device which diverge the network is called HUB. One HUB can connectfour gas chromatographs or GCIU. HUB also can be used for the divergence the line.

UPS (Uninterruptible Power Supply unit):This is the unit to protect the harddisk drive in GCAS from the accidental power down.

GCRB (Relay Box): Safety device for GCIU (type of protection “n”).

Documents Related to the Analyzer Bus System

GCIU

(1) GCIU Interface Unit nstallation Manual (TI 11B05B02-02E)

(2) GCIU GC Interface Unit (IM 11B5B2-01E)

(3) Analyzer Bus System (GS 11B5A1-01E)

(4) GC1000 Analyzer Bus System (TI 11B5A1-03E)

Operation Data

Operationg equipment is supplied with the operation manuals in the delivered packageand contain the following.

Instrument specifications General connection diagram

Related products

(1) ASMT Analyzer Server Maintenance Terminal Operation Guide (IM 11B5A1-01E)

(2) Analyzer Server User’s Manual (IM 11B5B1-01E)

(3) Hub GCHUB Installation Manual (TI 11B5C1-01E)

(4) GCMT Gas Chromatograph Maintenance Terminal Software Package OperationGuide (IM 11B3G1-02E)

(5) Capture It! Manual (IM 11B3G1-02E)

Is the System Ready?Before reading this manual, the following preparations must have been completed.

The system must be unpacked and installed in the correct place. The wiring for the power supply and others must be completed.

Please read the following General Precautions, before installing and using the GCIU.

General Precautions

CAUTION:(1) Take great care when carrying and installing (wiring) the GCRB. The GCRB

must be carried and installed very carefully (including wiring) by morethan one person (at least two people are recommended).

(2) Use the GCRB within the range of your purchase specifications.Yokogawa assumes no responsibility for problems resulting from use by thecustomer outside the purchase specifications.


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TI 11B05B02-03E

(3) Since the GCRB is precision instrument, take care when handling not tojolt of knock them.

(4) If the GCRB needs to be modified or repaired, please contact your nearestYokogawa representative. Yokogawa assumes no responsibility for resultswhere the customer or any third party has attempted to modify or repair theseproducts.

IMPORTANT(1) Read the attached instruction manual before operating the GCRB

(2) The instruments must be installed and operated according to the instructionmanual, approved drawings, and operation data.

(3) Do not hesitate to ask Yokogawa to modify or repair the instrument.Yokogawa assumes no responsibility for defects resulting frommodification or repair by the customer or unauthorized manufactures.

(4) Wiring worksWhen performing wiring, always using the flameproof packing adapter.

(5) Maintenance and RepairThe instrument modification or parts replacement by other than authorizedrepresentative of Yokogawa Electric Corporation is prohibited.


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Cautions

CAUTIONS OF USING EXPLOSION-PROTECTION INSTRUMENTSThe GCRB is designed to protect against explosion. When GCRB is used in a hazard-ous area, observe the following precautions.

(1) Kinds of explosion protection

CENELEC (ATEXdirective) : Ex Group II, Category 3G, EExnC IIC T6

(2) Installation site and environment

The GCRB specifications allow it to be used in hazardous areas as defined by Zone2.

(3) Wiring works

When performing wiring, always use the flame-proof packing adapter.

(4) Do not open when energized.

(5) Maintenance and checks

If any of the following damage occurs, inform a Yokogawa sales representative or the

Yokogawa sales division

1. If the exterior of the enclosures are damaged

2. If packings are cracked or conspicuously deformed

(6) Operation

Warning:

* GCRB shall not be opened unless the area is known to be nonhazardous, orunless all devices within have been de-energized.

<CENELEC>

* Only trained persons may use this instrument in a hazardous location.

* Do not open when energized.

Take care not to generate mechanical spark when access to the instrument andperipheral devices in hazardous locations.

(7) Maintenance and Repair

* The instrument modification or parts replacement by other than authorizedrepresentative of Yokogawa Electric Corporation is prohibited and will void theapproval of CENELEC certification.


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TI 11B05B02-03E

1. OVERVIEWGCRB is used with GCIU cer tified CENELEC (A TEX directive).

GCRB has rela ys to cut off ener gy intruding to the pressuriz ed enclosure (electr onicsection) of GCIU thr ough I/O signal fr om outside . These rela ys are activ ated by suppl yof DC electric resource from the pressurized enclosure (electronic section) of GCIU. Sothat when saf ety device 1 of GCIU turns off po wer suppl y to the pressuriz ed enclosure(electr onic section) of GCIU , DC power suppl y to the rela ys in GCRB is also turned off .Then, the ener gy fr om outside tinto GCIU is cut off .

1.1 Description and RatingsPower supply: 12 V DC

Power consumption: Max. 10 W

Operating ambient conditions: -10 to 50 ºC, 95%R.H. or less

Storage conditions: -40 to 85 ºC, No moisture condensation

Weight: Approximately 14 kg

Installation location: Well-ventilated place indoor s, free of vibration, direct sunlight,and reflected light and heat

Explosion protection: CENELEC (ATEX Directive) Ex Group II, Categor y 3G,EEx nC IIC T6

Signal Input / Output: 30 V DC, 500 mA max. 86 points

1.2 MS CodeTable 1.1

Model Option Code

GCRB...................

...................

...................

Relay Box

Always -N

Always N

Always N

-N -

N -

N -

Basic Code Description

.............................................

T01.eps


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TI 11B05B02-03E

1.3 Block Diagram

F0101.EPS

A36 D36A1 D1

A37 D37A2 D2 Signal line

(Field side)Signal line(GCIU side) A60 D60

A35 D35

A125 D125

A126

+

- D126

RELAY BOARD 2

Power supply(12V DC)

B95 C95B73 C73B96 C96B74 C74 Signal line

(Field side)Signal line(GCIU side)

B124 C124B94 C94

B125 C125

B126 C126

RELAY BOARD 1

Connected

Figure 1.1



TI 11B05B02-03E

1.4 External DimensionsUnit : mm

300 410 200

Maintenance space

1000

410

400

140

120

580 520

(30)

30 Cable entry : 6-ø25

4-ø10.5 holes

400

Figure 1.2


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TI 11B05B02-03E

1.5 Standard Performance

EMC standard

Emission

Complying Standard : EN55011 Group 1 Class AEN61326 Class AC-tick

Test item: Electromagnetic radiation disturbanceFrequency range: 30 MHz - 1 GHzBasic standard: Class A CISPR16-1 and CISPR16-2

Immunity

Complying Standard : EN61326 Class A

No. Test Item Test specification Basic Standard Preformance Criteria*1 4kV(contact)

8kV(air)2 80 to 1000MHz

1.4 to 2GHz10V/m(unmodulated)80% AM (1kHz)

3 2kV5/50 Tr/Th ns5kHz REP.

4

5 0.15 to 80MHz3V (unmodulated)80% AM (1kHz)Source impedance150Ω

IEC 61000-4-2 A

IEC 61000-4-3 A

IEC 61000-4-4 A

IEC 61000-4-5 A

IEC 61000-4-6 A

Electrostatic dischargeRatio-frequency electromagnetic fieldAmplitude modulatedFast transients common mode

Surge

Radio-frequency common modeAmplitude modulated

Input power supply and power supply network 1kV (Line to Line) 2kV (Line to Ground)I/O signal/control 1kV (Line to Ground)

* See Note 1

Note: Definition of perf ormance Criterion A

• The relay doesn’t operate faulity .



TI 11B05B02-03E

1.6 Data Plate


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<Toc> <Ind> <2. INSTALLATION AND WIRING > 2-1

TI 11B05B02-03E

2. INSTALLATION AND WIRINGIf GCRB is to be installed in a hazardous location, do the wiring according to the appli-cable explosion-proof requirements.

2.1 Installation(1) Installation Site

Install the GCRB where the following conditions are met :

(a) Specified environment conditions (atmospheric gases) are satisfied if used in ahazardous area.

(b) Less vibration.

(c) Not subject to rainfall or direct sunlight.

(d) No corrosibe gas or few dust.

(2) Unpacking

The model GCRB weights about 14kg. Unpacking it near the instlallation site.

Handle it carefully so that it does not fall.

(3) Installation

To securel y install the GCRB on a wall, use a nut and a bolt f or each hole .


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TI 11B05B02-03E

2.2 Wiring

2.2.1 General Cautions on Wiring

CAUTION

• Lay the signal wiring and electrical wiring inseparate conduit pipes or duct, respectively.

• Make independent grounding having a grounding resistance of 100 Ω or less.

NOTE

In the case of locking the door, please use the attached key.

CAUTION

Be sure to lock the door after opening the door.

2.2.2 Kinds of WiringThe following kinds of wiring are required for GCRB.

The wiring required varies with the specification.

(A) Gounding circuit

(B) Signal lines (GCIU side)

(C) Signal lines (Field side)

2.2.3 Recommended Cables(A) Gounding circuit: 2.0mm2

(B) Signal lines (GCIU side): 0.75mm2 to 1.5mm2 , 10m or lessCable shield is required(The shield of signal lines (GCIU side) should be connected to the groundingterminal inside the GCIU.)

(C) Signal lines (Field side): 0.75mm2 to 1.5mm2 , 1000m or lessCable shield is required(The shield of signal lines (Field side) should be connected to the groundingterminal inside the GCIU.)

Note : Use “MKKDSN” Series terminals (manufactured by Phoenix Contact K. K.) for the Signal lines (B), (C).For these wiring connections, use AI series crimp-on terminals also manufactured by the company. Four typesof crimp-on terminals are used to meet wire diameters (see the table below).Please peel off the cover of wire by 5mm if you do not use the terminal and contact with the terminal. 5mm isthe manufacturer’s recommendation values.

Table 2.1

0.75mm2 Less than 2.8mm2 AI 0.75-6GY

1.0mm2 Less than 3.0mm2 AI 1-6RD

1.5mm2 Less than 3.4mm2 AI 1.5-6BK

Wire Diameter Terminal TypeOutside Diameter

T0201.EPS



TI 11B05B02-03E

2.2.4 Precautions on Wiring

<CENELEC>

WARNING

• All wiring shall comply with local installation requirements and local electrical code.• The cable entry devises shall be of a certified flameproof type that meet or exceed IP54, suitable for the conditions of use.

2.2.5 Grounding Wire Termination and Signal Cable Shield(1) termination

Use solderless lugs for Grounding Wire and Signal Cable shields (See Figure 2.1).

(2) Solderless (crimp-on) lug specifications

The solderless lug to use m ust ha ve the dimensions given in Table 2.2 accor ding to thenominal cross sectional area of the power cable for which the lug is to be used.

Table 2.2 Solderless Lug Dimensions

Nominal cross sectional area

Screw used(mm)

Hole diameter(mm)

Lug outside diameter

(mm)

Lug length(mm)

Insulation covering inside diameter (mm)

Remarks (Note)(Example of applicable

solderless lug)

1.25mm2 4 4.3 or more 8.7 or less About 21 5.8 or less AMP 170781-1JST V1.25-4

2.0mm2 4 4.3 or more 8.7 or less About 21 5.8 or less AMP 170782-1JST V2-4

T0202.EPS

Note :AMP: Japan AMP Co., Ltd.JST: JST Co., Ltd. (Insulators 0.8 mm 2 or more in size are optionally available.)

F0201.EPS

Hole diameter

Lug outsidediameter

Lug length

Insulation covering inside diameter

C

Figure 2.1 Solderless Lug

<CENELEC>

WARNING

The cable entry devices and the blanking elements shall be of acertified flameproof type that meet or exceed IP54, suitable for theconditions of use and correctly installed.For external earthing or bonding connection a cable lug shall be usedso that the conductor is secured against loosening and twisting andthat contact pressure is permanently maintained.



TI 11B05B02-03E

Grounding circuit

Figure 2.2

CAUTION

• For protective grounding of terminal connector-type devices, connect to the terminal.



TI 11B05B02-03E

2.2.7 Signal LinesRefer to Figure 2.2.

(1) GCIU side

Table 2.3

Terminal No. Signal Terminal No. SignalTerminal No. Signal

Digital output(Enclosure pressure drop alarm)

B85 (NO)A43 (NO)A1 (NO)

B86 (NC) Digital output 1A44 (NC)A2 (NC)

B87 (COM)A45 (COM)A3 (COM)

Digital output(System alarm)

Digital output 3

B88 (NO)A46 (NO)A4 (NO)



Digital output 2

Digital output 6

B91 (NO)A49 (NO)A7 (NO)



Digital output 5

Digital output 9

B94 (NO)A52 (NO)A10 (NO)



Digital output 8

Digital output 12

B97 (NO)A55 (NO)A13 (NO)



Digital output 11

Digital output 15

B100 (NO)A58 (NO)A16 (NO)



Digital output 14

B113 (+)

B114 (-)Analog input 1Analog input 3

B115 (+)

B73 (+)A31 (+)

B116 (-)Analog input 4

B74 (-) A32 (-)Analog input 2

Analog input 6

B117 (+)

B75 (+)A33 (+)


B76 (-)A34 (-)Analog input 5

Analog input 9

B119 (+)

B77 (+)A35 (+)



Analog input 12

B121 (+)

B79 (+)A37 (+)



Analog input 15

B123 (+)

B81 (+)A39 (+)


Power supply


A125,B125 (+)

A126,B126 (-)

T0203.EPS



TI 11B05B02-03E

(2) Field side

Table 2.4

Terminal No. Signal Terminal No. SignalTerminal No. Signal

Digital output(Enclosure pressure drop alarm)

C85 (NO)D43 (NO)D1 (NO)

C86 (NC) Digital output 1D44 (NC)D2 (NC)

C87 (COM)D45 (COM)D3 (COM)

Digital output(System alarm)

Digital output 3

C88 (NO)D46 (NO)D4 (NO)



Digital output 2

Digital output 6

C91 (NO)D49 (NO)D7 (NO)



Digital output 5

Digital output 9

C94 (NO)D52 (NO)D10 (NO)



Digital output 8

Digital output 12

C97 (NO)D55 (NO)D13 (NO)



Digital output 11

Digital output 15

C100 (NO)D58 (NO)D16 (NO)



Digital output 14

C113 (+)

C114 (-)Analog input 1Analog input 3

C115 (+)

C73 (+)D31 (+)

C116 (-)Analog input 4

C74 (-) D32 (-)Analog input 2

Analog input 6

C117 (+)

C75 (+)D33 (+)


C76 (-)D34 (-)Analog input 5

Analog input 9

C119 (+)

C77 (+)D35 (+)



Analog input 12

C121 (+)

C79 (+)D37 (+)



Analog input 15

C123 (+)

C81 (+)D39 (+)


Power supply


D125,C125 (+)

D126,C126 (-)

T0204.EPS

2.2.7 Terminal connection of shielded signal cables for CENELECThe shield of a signal line (Field side) to be connected to the GCRB should be con-nected to the earth bar inside the GCRB.


Revision Record

Manual No. : TI 11B05B02-03E

Title : GCRB Relay Box Installation Manual

Mar. 2002 / 1st EditionNewly published

Dec. 2006 / 2nd EditionSection 1.5: Safety regulation is updated accordingly.

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